Abrasive article and method of grinding

Abstract

An abrasive article includes a backing, abrasive particles secured to the backing, and a size coat provided over the abrasive particles, the size coat comprises a binder resin, at least one filler material and at least one lubricant material having a melting temperature of at least about 200 degrees F. A method of grinding aluminum using such an abrasive article is also described.

What is claimed is: 
     
       1. An abrasive article comprising:
 a backing; 
 abrasive particles secured to the backing; and 
 a size coat provided over the abrasive particles; 
 wherein the size coat comprises a binder resin, at least one filler material and at least one lubricant material having a melting temperature of at least about 200 degrees F.; 
 wherein: 
 the lubricant material comprises a Fischer-Tropsch wax that is a solid powder at room temperature, the solid powder having an average particle size of at least 1 micron and no greater than 50 microns; 
 the binder resin comprises a phenolic resin; and 
 the filler material comprises potassium aluminum fluoride (PAF); 
 wherein the wt % ratio of phenolic resin to the combination of the filler material and the lubricant material is at least 1:4 and no greater than 4:1. 
 
     
     
       2. An abrasive article as defined in  claim 1 , further comprising a make coat layer bonding the abrasive particles to the backing. 
     
     
       3. An abrasive article as defined in  claim 1 , wherein the size coat comprises at least about 10 wt % and no greater than about 80 wt % binder resin. 
     
     
       4. An abrasive article as defined in  claim 3 , wherein the size coat comprises at least about 1 wt % filler material and no greater than about 75 wt % filler material. 
     
     
       5. An abrasive article as defined in  claim 4 , wherein the size coat comprises at least about 1 wt % lubricant material and no greater than about 30 wt % lubricant material. 
     
     
       6. An abrasive article as defined in  claim 1 , wherein the abrasive article is a coated abrasive article. 
     
     
       7. An abrasive article as defined in  claim 1 , wherein the abrasive article is at least one of a belt, fiber disc, and a nonwoven abrasive article. 
     
     
       8. An abrasive article as defined in  claim 1 , wherein the abrasive particles are at least one of alumina, silicon carbide and diamond. 
     
     
       9. An abrasive article as defined in  claim 1 , wherein the filler material comprises a blend of at least two different filler materials. 
     
     
       10. An abrasive article as defined in  claim 1 , wherein the binder resin further comprises epoxy. 
     
     
       11. A method of grinding aluminum, comprising the steps of providing an abrasive article as defined in  claim 1  and bringing the moving abrasive article into contact with the aluminum.